Mailing folder



Feb. 11, 1969 C A 3,426,957

MAILING FOLDER Filed Dec. 16, 1966 INVENTOR. 5044a) J M6 144 a4 BY 45!, M g w r WTTORNEYS United States Patent 3,426,957 MAILING FOLDER Richard J. McCall, 1500 5. Shore Drive, Crystal Lake, Ill. 60014 Filed Dec. 16, 1966, Ser. No. 602,284 US. Cl. 229-40 Int. Cl. B65d /28, 27/28 2 Claims ABSTRACT OF THE DISCLOSURE This invention relates to one-piece foldable boxes and more particularly to a foldable corrugated mailer box having a one-piece blank characterized by the utilization of three-sided air-cells protecting the side edges of the interior box chamber.

It is an object of the present invention to provide an improved box construction especially adaptable as a mailer box and which utilizes a minimum amount-of stock.

It is a further object of the present invention to provide three-sided air-cells at opposite ends of a box protecting the contents of the box.

Yet another object of the present invention is to provide a sequentially foldable box which incorporates an increased amount of strength because of the combination of panels and flaps and the respective locations thereof.

It is a still further object of the present invention to provide a box having a bottom wall which is narrower than the other walls to form indented air-cells.

Many other features, advantages and additional objects of the present invention will become manifest to those versed in the art upon making reference to the detailed description which follows and the accompanying drawing in which a preferred structural embodiment of a box incorporating the principles of the present invention is shown by way of illustrative example.

On the drawings:

FIGURE 1 is a development of a one-piece blank used to construct the box of the present invention;

FIGURE 2 is a somewhat reduced view showing the partial blank of FIGURE 1 with side, rear, bottom and flap-tucker panels moved into assembly position;

FIGURE 3 is a partial perspective side view of the assembled box showing one of the air-cells; and

FIGURE 4 is a cross-sectional view taken substantially along the line IVIV of FIGURE 3.

As shown on the drawings:

The box of the present invention is made of a sheet form member such as a double face sheet form corrugated paper blank indicated generally at and having the usual laminar construction consisting of corrugations 34 (as best seen in FIGURE 4) with the double faces provided by an inside surface sheet and an outside surface sheet. The outside surface sheet may contain any desired indicia-bearing information.

In accordance with the principles of the present invention, the die cutting process is carried out to afiford substantially simultaneous cutting and scoring operations. Thus, the blank 10 is not only cut to the proper peripheral configuration but the desired cut lines are formed in the blank, as well as the proper scoring lines to divide the blank into a plurality of panels disposed in a predetermined position. It has been found that the box of the present invention can more readily be formed in a strengthened condition if the corrugations are so-aligned as to run in a direction so that the four principal score lines provided on the body portion of the blank extend substantially co-extensively with the corrugations, thus contributing to the ease with which the box of the present invention may be folded to an assembled condition and contribute to the overall strength of the box.

More specifically, it will be noted that the sheet form member 10 comprises a main body portion having a first score or score line 11, thereby providing a first panel in the main body portion which will be referred to herein as bottom wall 12. A second score line 13 is formed in the body portion in spaced relation to score line 11, thereby forming a second panel in the main body portion adjacent the first panel and such panel will be referred to herein as rear wall 14.

The body portion of the sheet form member 10 is provided with a further score line 15 which is spaced from score line 13, thereby forming a third panel adjacent the rear wall 14, which third panel will be referred to herein as top wall 16. A further score line 17 is formed in the body portion in spaced reationship to score line 15, thereby forming a fourth panel in the main body portion adjacent top wall 16 and such panel will be referred to herein as front wall 18. The remaining fifth panel is provided with a relief margin as at 19 with rounded corners as at 20 and has a preforated score line 21 to facilitate bending the fifth panel thereat. The fifth panel shall be referred to herein as folding flap member 22 composed of trailing flap member 22a and leading flap member 22b. The perforated score line 21 is not absolutely necessary and in certain embodiments of the invention it may be omitted to obtain satisfactory results.

It will be specifically noted that each of the scores or score lines 11, 13, 15, 17 and 21 extend longitudinally co-extensively with the corrugations 34 (best seen in FIGURE 4 in accordance with the principles of the present invention to provide added strength at the peripheral portions of the assembled mailing folder.

The box of the present invention is further characterized by the provision of a flap on each side of bottom wall 12, which flap is adapted to constitute a two-panel side member. Thus, it will be noted that blank 10 is provided with longitudinal score lines 23 and 24 on either side of the bottom wall 12 extending transversely to the direction of the corrugations thereby forming an integral hinge connection between the respective flap members and the bottom wall 12. Each flap is provided with an additional longitudinal score line 25 and 26, respectively, in spaced relationship from score lines 23 and 24 to form side walls 27 and 28 with reinforcement flanges 29 and 30.

The spacing dimension between score lines 23, 25 and 24, 26 is substantially the same as the spacing dimension between the score lines .15 and 17. However, the spacing between score lines 11 and 13 is greater than the spacing just discussed by an amount substantially equal to the thickness of the corrugated blank 10. This relation of spacing dimensions between score lines 23, 24; 24, 26- and 15, 17 and score lines 11 and 13 allows the formation of a box that is substantially rectangular in shape despite the fact that portions of the assembled box has more than one layer of corrugated stock.

It will be noted that the material along the outer edges of score line 11 has been cut-out as at 31 and 32, respectively. The cut-outs 31 and 32 allow side walls 27 and 28 to fold upwardly from bottom wall 12 along score lines 23 and 24 to expose extending edge portions 14a and 14b of rear wall 14. The length of the cut-outs 31 and 32 is substantially the same length as the relief margins 19a and 19b along score line 18. It will be realized, of course, that other suitable lengths could be utilized.

As best seen in FIGURE 2, there may be provided an adhesive or glue line 33 substantially in the center of the outer face of trailing flap member 22a to form a sealing means for the assembled box. As will be realized, of course, other suitable sealing means may also be utilized.

In assembling the box, substantially as illustrated in FIGURES 2 and 3, the two-panel side members 27, 29 and 28, 30 are first folded upwardly along score lines 23 and 24, respectively, into substantially perpendicular positions in respect to bottom wall 12. Then the reinforcement flanges 29 and 30 are folded inwardly to subtantially perpendicular positions in respect to side walls 27 and 28 and substantially parallel but spaced relationship to planar bottom 12.

Next, the bottom wall 12 is folded upwardly to a substantially perpendicular position in respect to planar top wall 16 along score line 11. The bottom wall is then sequentially folded downwardly along score line 13 causing rear wall 14 to assume a substantially perpendicular position in respect to both bottom wall 12 and top wall 16. Bottom Wall 12 is moved downwardly until the outer faces of the reinforcement flanges 29 and 30- contact the inner faces of the top wall 16 so that the bottom wall 12 assumes a substantially parallel position in respect to the top wall 16.

Substantially at the same time the leading flap member 22a is folded in an upward direction at perforated score line 21 so that its outer face portion is brought into contact with the inner face portion of bottom wall 12. During this time, trailing flap member 22b is folded upwardly along score line 17 toward bottom wall 12 so as to contact its outer face with the inner face of bottom wall 12. This sequential folding process forces leading flap member 22a to be tucked into the now-formed box chamber and it also causes front wall 18 to assume a substantially perpendicular position in respect to both bottom wall 12 and top wall 16.

As best seen in FIGURE 3, when the sequential folding process is complete, there are substantially identical but opposed three-sided air-cells formed on either side of the assembled box. The air-cell seen at FIGURE 3 is defined by the extending edge portion 14a of rear wall 14, the extending edge portion 16:: of top wall 16 and the extending edge portion 18a of front wall 18. As will be realized, of course, a corresponding air-cell is formed on the opposite side of the box from that shown in FIGURE 3 and is defined by corresponding extending portions 14b, 16b and 18b.

The three-sided air-cells provided by the novel configuration forming the mailer box of the present invention have found to provide exceptional protection to the interior edges of the box while at the same time utilizing a minimum amount of stock. These indented air-cells provide exceptional safety for the contents of the box-like mailer folder as they allow relatively negligent or rough handling thereof without concern as to content damage. This type of box is especially useful as a mailer folder wherein books or other similar objects needing edge protection can be readily shipped with assurance that the books, etc. will arrive in their original condition. The extending edge portions of the various walls defining the aircells are so-aligned that the corrugations of the blank are disposed in a parallel relationship to the planes of the top and bottom walls so as to present a substantially perpendicular or end-grain configuration to any outside object coming into contact with the extending edge portions. Thus, the corrugations present substantially rigid end portions which are not easily bendable or otherwise damaged. 1

The three-sided configuration allows complete protection of all the interior edges of the mailer folder while at the same time requires only a minimum amount of stock.

FIGURE 4 is substantially a cross-sectional view taken along line IVIV of FIGURE. 3 showing a somewhat modified embodiment of the present invention. Bottom wall 12 is shown as having its inner face in planar contact with the outer face of flap member 22. The assembled box is shown as being held in position by a simple strip of adhesive tape 35, which allows relatively easy opening of the box and provides sufficient means to hold the bottom wall 12 in proper relationship to the front wall 18. Top wall 16 is shown as having its inner face in planar contact with the outer face of reinforcement flange 29. The corrugations 34 of the stock are illustrated as forming end-grain configurations for added edge strength.

Although minor modifications may be apparent to those skilled in the art, it should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope and spirit of my contribution to the art.

I claim as my invention:

1. A mailer box comprising a one-piece blank scored, stripped and cut to form a five-panel section forming bottom, rear, top and front walls having relatively perpendicular edges with a folding flap member which is foldable in a first direction, a plurality of two-panel flap mem bers forming side walls hingeably integrated with said bottom wall and foldable in a direction generally normal to said first direction, said bottom wall being generally equidistant indented from said rear wall, said two-panel flap member being sequentially foldable into opposing side walls having reinforcement flanges in generally parallel relationship to said bottom wall, said bottom wall being sequentially foldable into a generally parallel relationship with said top wall, said front wall being sequentially foldable into a substantially perpendicular relationship to said top and bottom wall, said bottom wall defining substantially rectangular extending edge portions along said rear wall, said folding flap member being sequentially foldable into substantially planar relationship with said top and bottom wall, said folding flap member being indented from said front wall and being provided with rounded corners at the outer extremities thereof, and a plurality of three-sided air-cells extending beyond said side walls being defined by said rear, top, and front walls.

2. A mailer box comprising a one-piece blank scored, stripped and out along substantially perpendicular lines to form a bottom, rear, top and front wall with a folding flap member, and opposing two-panel flap members hingeably integrated with said bottom Wall forming respective side walls, said bottom, rear, top, front, side walls and folding flap member being sequentially foldable along said perpendicular lines to form a substantially rectangular chamber, said folding flap member being indented from said front wall and being provided with rounded corners at the outer extremities thereof to facilitate folding said folding flap member into said rectangular chamber, said bottom wall being generally equidistantly spaced inwardly from the peripheral edges of said rear, top and front walls to define opposing air-cells outside said rectangular chamber when the box is in an assembled position thereby protecting the interior edges of said chamber.

References Cited UNITED STATES PATENTS 3,253,770 5/ 1966' Black 229-40 3,302,851 2/ 1967 Johnson 2294O XR 3,341,908 9/1967 Lock 229-40 XR FOREIGN PATENTS 360,648 4/1962 Switzerland.

DAVIS T. MOORHEAD, Primary Examiner.

US. Cl. X.R. 206-46; 229-87 

